Prefabricated door frame and molding structure



Oct. 22, 1963 R. L. DAY ETAL 3,107'759 PREFABRICATED DOR FRAME AND MOLDING STRUCTURE Filed July 29, 1960 2 Sheets-Sheet 2 INVENTORS. E0852? L' DRY Hqeey L. MLL/HMS gyyzm 1% r' TOENEYS.

United States Patent Office 3,l07,'i50 Patented Oct. 22, 1963 PREFABRHCATED DR "i '1 MGDENG STRUCTURE Robert L Day, Ein-bank, 'and Harry L. Williams, North Hollywood, Calif., assignors to American Frame Company, Los Angeles, Calif., a corporation of California Filed July 29, 1%0, Ser. No. 46,130 6 Claims. (Ci. 189-136) This invention relates to a frame construction and particularly to a prefabricated metal frame, such as for a door.

The appearances of previous metal door f-rames have been severely marred by the means used to install them. Many attempts have been made to utilize camouflaging techniques, tanalogous to those employed with Wood materials. None of these methods have been successful, since the metal is not a comparable surface. The primary object of this invention is to provide an arrangement in which the exposed surfaces of the metal frame will not be the subject of any disfigurations.

In order to achieve the foregoing result, use is made of a novel prefabricated frame and detachable trim structure.

Another object of this invention is to provide a unique fastening arrangement whereby the trim structure can be made of material having a uniform :cross-section. Accordingly, the trim can be inexpensively made.

Still another object of this invention is to provide a unique means for fastening `a trim structure of this character in which an effective catch is formed by striking tabs from the flanges of the frames. Thus it is unnecessary to 'aflix any separate parts to the metal frame, and economical manufacture of the unit is facilitated.

Still another object of this invention is to provide ya prefabricated trim structure that has miter corner joints that can be made to precisely fi-t by simple adjustments at the time of installation, and despite slight departures of the dimensions of the parts or their relationship from a desired standard. i

Still another object of this invention is to provide a unique bracket or guide for 'the Corners of the trim members, -to assist the catches in holding the trim in place, and that, like the catches, allows the trim members to be adjusted .to compensate for the dimensional variaftions.

Still another object of this invention is to provide an improved relationship whereby the molding abuts the finished wall, entirely concealing all but the inner margin of the frame fianges, thereby providing an unnsually neat appearance. i

It is another object of this invention to provide a metal frame and trim structure for various Wall openings 'that can be easily installed.

This invention possesses many other xadvantages and has other objects which may be made more 'clearly appatent from consideration of one embodiment of the invention. For this purpose, there is shown a form in the drawings accompanying and forming a part of this specification. This form will now be described in detail, illustrating the general principles of the invention; but it is to be nnderstood that this detailed description is not 'to be 'taken in a limiting sense, since the scope of this invention is best defined by the appended claims.

Refern'ng to the drawings:

'FIGURE 1 is a pictorial view of a door frame and'l molding structure embodying the invention;

FIG. 2 is an enlarged fragmentary view of the corner frame 'and trim structure;

FIG. 3 is an enlarged sectional view taken along the plane indica'ted by line 3-3 of FIG. 1;

FIG. 4 is an enlarged sectional view taken -along the plane indicated by line 4-4 of FIG. 2;

FIG. 5 is an exploded pictorial view of the corner structure;

PIG. 6 is 'a pictorial view illustrating how the molding structure is attached to the door frame; and

FIG. 7 is an enlarged sectional view taken along the plane indicated by line 7-7 of -FIGURE 2.

In FIG. 1 'there is illustrated a metal frame structure installed in a doorway. The frame is composed of three pieces, 'as shown in PIG. 6. Two substantially similar members 25 and 30 -are placed at the lsides of the doorway to form jambs. One of the jamb members 25 mounts the hinge-posts 26, and the other of the jamb members 30 mounts |the strike plate 31. The upper edges of the jambs abut a head piece 20 which extends across the top of 'the doorway. Together the head piece 20 and the jamb members 25 and 30 provide a complete frame for the doorway.

The head piece 20 and the jambs 25 and 30 are cut from ident-ioal stock, as shown in FIG. 5. A detailed description of the cross-sectional configuration of the jamb member 30 suffices 'as a description of the other frame members 20 and 25.

The jamb member 30 has a configura-tion substantially as a channel, as shown in FIGS. 3 and 5, there being flanges 22 extending from opposite sides of a central connecting portion 23. 'Ilhe flanges 22 embrace opposite sides of the finished wall 50 (FIG. 3) cornered. The central portions of the jambs are tcontiguous with the central por-tions of the head piece. The ends of the head pieces' intermediate depression 24 are relieved to avoid interference and to provide a fitted relationship.

The frame members are 'attached to the wall (as shown best in FIG. 3) by screws 42, 'nails, or similar fastening means. 'llhe screws 42 pass through apertures 40 in both of the fianges ion each frame member. The 'apertures 0 extend in spaced relationship along the length of each ange.

The frame members are uniformly fabr'icated, 1and by virtue of their fitted .frelationship the precise dimensions of the finished doorway are pre-determined. 'Fhe fitted relationship is iachieved by virtue of the guide tabs 19 which are formed by folding downwardly, that is in the same direction as the intermediate depression 24, the ends of the central por-tion 23 of the head piece 20 exclusive of the intermediate depression 24. These tabs 19 form a corner angle somewhat greater than ninety degrees, and provide 'an eifective and eificient means of guiding the Vertical jamb members 25 and 30 into the proper position' relative, to the head piece 20. Therefore, the door mounted on the hinge jambs 25 will precisely fit, regardless of variations in any particular opening. T'hus, the width of the opening in which the frame members are accommodated may equ'al or exceed the eXact length of the head piece20 without distfurbing the fit of the door in the finished frame.

In order to provide 'a finished appearance the frame is provided with trim molding. This molding conceals the fastening means 40-42 and also hides other unattractive areas of the fianges, as for example, the corner intersections of the head piece 20 and the jambs 25 and 30.

The trim is aflixed to the flanges on both sides of the doorway. On each side the trim consists of three pieces adapted to be secured to the three frame members. Two similar side mold pieces or molding members 17 and 18 are secured to the flanges of the jambs 25 and 30. A top mold piece or molding member 10 is 'affixed to the flange of the head piece 20'. Each of these trim molding members is pre-cut to conform precisely to the length of the corresponding frame member. The trim molding members completely overlie the flanges 23, except for a narrow enomo strip adjacent the central section of the frame, as shown in FIG. 2.

'The trim members 10, 17, and 18 are cut from stock material of unform cross-section that may expeditiously be made by roll forming processes or the like. The trim has a cross-section-configuration as a channel (PIG. 4), with the fianges 15 and 16 extending toward the wall. The outer flanges 16 of the trim members actually contact the wall 50 beyond the edges of the corresponding frame fianges 22, thereby completely concealing them. The inner flanges of the trim members contact the corresponding frame flanges 22 adjacent the doorway.

In this example, the inner flange 15 is somewhat narrower than -its opposite member 16. Therefore, the central section of the trim tapers inwardly of the doorway on all sides.

The upper ends of the side trim members 17 and 18 are fitted to opposite ends of the top |trim member 10. For this purpose, the ends of the trim members are cut at an angle of 45 to provide edges 11 forming a miter joint. To maintain the right angle relationship, the trim members are telescoped about 'a night 1angle corner guide 45. 'Ihe guide is hidden by the engaged trim members.

The right angle corner guide 45 is a unitary body, having legs extending at right angles to each other from a common junction, symmetrically with respect to an aXis a drawn bisecting the right angle. Each leg (FIG. 7) of the guide or bracket extending from the axis of symmetry is slightly smaller, but of substantially |the same channel configuration as the trim members in order snugly 'to fit therein. The mitre edges of the molding members abut each other adjacent the axis of symmetry a as they are fully telescoped over the guide 45.

The fianges 15 -and 16 have inwardly turned ends 13 and 14, as shown in FIG. 4, that form a restricted opening co-operable with catches extending in spaced, aligned relationship along the frame flanges 22.

Each of the catches are struck in two parts, 35 and 36, from the parent metal of the fiange 22. The parts 35 and 36 extend `as tabs from opposite ends of a rectangular cut out or opening 38 of the flange 22. The combined lengths of the .tabs precisely equal the length of the opening 38. Hence the two parts of each catch are formed by a single I or H-type cut in the fiange 22. The catch part 35 is curled to provide a re-entrant latching surface facing in a direction away from 'the other catch part 36, and located near the base of the frame flange 22. The catch part 36 is oriented to determine an overhanging relationship of the trirn molding member with respect to the flange edge. Thus, the other catch part 36 is bent outwardly to extend beyond the edge of the fiange 22, the projecting end being curled to provide a re-entrant latching surface facing in a direction away from the first catch part 35. The terminal portion of the catch part 36 not only abuts the edge of the flange 22, but is forced inwardly to create an indentation in the flange surface that secures the catch part 36 firmly in place.

In order to install .the trim, the molding members 10, 17 and 18 are pre-assembled with the aid of the corner brackets or guides 45, as shown in FIG. 6, yand the inwardly turned edges 13 and 14 of the trims fianges will progressively engage 'the catches 35, 36 as the trim is rotated upwardly about 'an aXis passing through the lower ends of 'the side members 17 and 18. The lower ends of .the side members 17 and 18 are located at the lower ends of the fianges 22.

In the present instance, the fianges 15 and 16 flex over the respective latching surfaces provided `by |the :catch parts 35 and 36, -and resiliently snap' in place. However, the required resilient exure could be achieved by one or both of the catch parts 35 or 36.

Finally, the top molding member 10 is snapped in place. If the Vertical jamb members 25 and 30 are not precisely situated at the bases of the tabs 19, an imperfect fit may result between the horizontal trim member of the miter joints may become slightly misaligned, but` not noticeably so. The inner corner of the guide 45 is relieved, as at 46, to preclude interference due to such adjustment, `and vto allow the guide 45 to fit the trim molding members even though .they pass on opposite sides of the symmetry axis a to maintain abutting relationship. The frame and trim can be fabricated of any appropriate metal and finished as desired.

'The inventors claim:

1. A metal frame structure for a door opening or the like fot-med in a wall, comprising: a pair of spaced side frame members and a top frame member coupled to the upper ends of said frame members, the three frame members each being of elonga'te channel fo'rrn providing opposed side flanges a'dapted to overlie the two surfaces of the wall and thereby frame ythe opening; a trim molding member for each of said frame members made of resilient material and extending along one flange of the respective frame member, said trim member being of elongate channel form With inwandly turned fianges along its two opposite lengthwise edges, said trim member having one of said edges located beyond the lentgthwise edge of said yone flange 'to engage the wall, thereby concealing the edge of said one flan-ge; and each of said frame member-s having means integrally formed from 'the material of said one flange securing the trim member to said one flange, said vsecuring means comprising two series of spaced tabs, the

first series of tabs :being spaced inward'ly from the lengthwi'se edge of said one flanfge and each having a curved l-atching surface, the second series of tabs being formed along said edge of said one flange and each having a curved 'latching surface extending beyond said edge of said one flanige and being reversely folded and having its end rigidly secured to said one flange, said inturned fianges of said trim members being resi'liently engaged about curved l-atching surfaces of said two series of tabs.

2. A metal frame structure as set fo'rt-h in clai'm 1, Wherein said two series of tabs are formed from I-shaped cuts -in said one flange, the tabs of said second series being folded substanti'ally outwardly from the center axis of said one flange to project beyond said edge of said one flange, and the :tabs of said first series being tightly eur-led to form said latching surface.

3. A metal fname structure as 'set forth in claim 2, wherein the latching surfaces of both series of taJbs are substantially semiecylindrical, and said end of each tab of said second series is 'clinched lto said one flange.

4. A metal frame structure as set forth in claim l, wherein each end of said top frame member is provided With 'a depending tab engaging the top end of the respective side frame member.

5. A rnet'al frame structure 1as set forth in claim 4, wherein each end of said top frame member is provided With 'additional 'depending means aXially spaced from the respective depending ta'b by a distance su'bst'antia'lly eq-ual to the 'transverse 'dimension of that poi'tion of the respective side frame member received there'between, said depending tab and depending means forming 'a slot engaging said side frame member on two opposite surfaces th'ereof.

6. A ymetal frame structure as set forth in claim 1, where'in the trim members of the side frame members abut the trim member of the top frame member in Vmiter joints, and further including a corner lbracket for each miter joint, each corner .'bracket having a lfirst arm telescopically received interionly of 'the respective end of said top frame trim member and a second arm telescopical-ly received interionly of the miter joint end of the respective of the trim members in fomnng the m'i'ter joint.

References Cited in the file of this patent UNITED STATES PATENTS Johnson Feb. 12, 1929 Baum Dec. 8, 1931 6 Heijmer Fe'b. 13, 1951 Barraoo Oct. 25, 1955 Herr Apr. 10, 1956 Banoroft Ian. 8, 1957 Goidheng July 15, 1958 Viets Nov. 24, 1959 Kiehl Dec. 8, 1959 LaueT Mam. 8, 1960 

1. A METAL FRAME STRUCTURE FOR A DOOR OPENING OR THE LIKE FORMED IN A WALL, COMPRISING: A PAIR OF SPACED SIDE FRAME MEMBERS AND A TOP FRAME MEMBER COUPLED TO THE UPPER ENDS OF SAID FRAME MEMBERS, THE THREE FRAME MEMBERS EACH BEING OF ELONGATE CHANNEL FORM PROVIDING OPPOSED SIDE FLANGES ADAPTED TO OVERLIE THE TWO SURFACES OF THE WALL AND THEREBY FRAME THE OPENING; A TRIM MOLDING MEMBER FOR EACH OF SAID FRAME MEMBERS MADE OF RESILIENT MATERIAL AND EXTENDING ALONG ONE FLANGE OF THE RESPECTIVE FRAME MEMBER, SAID TRIM MEMBER BEING OF ELONGATE CHANNEL FORM WITH INWARDLY TURNED FLANGES ALONG ITS TWO OPPOSITE LENGTHWISE EDGES, SAID TRIM MEMBER HAVING ONE OF SAID EDGES LOCATED BEYOND THE LENGTHWISE EDGE OF SAID ONE FLANGE TO ENGAGE THE WALL, THEREBY CONCEALING THE EDGE OF SAID ONE FLANGE; AND EACH OF SAID FRAME MEMBERS HAVING 